Sustainable Thermal Post-Processing of PLA 3D Prints: Increased Dimensional Precision and Autoclave Compatibility

Abstract

This study investigates the thermal properties and sterilization efficacy of polylactic acid (PLA) components fabricated via fused deposition modeling (FDM), focusing on PLA’s compatibility with autoclave sterilization protocols. While PLA is extensively recognized for its biobased and biodegradable characteristics, its limited thermal stability has traditionally restricted its application in high-temperature sterilization settings, such as in medical contexts. In our research, we examined three distinct specimen geometries—cylindrical, rectangular, and curved—subjecting them to thermal post-processing through constrained annealing, employing salt or silicone as the embedding medium. Following this process, we exposed the specimens to elevated temperatures, simulating typical sterilization conditions. The outcomes indicated that the annealed PLA specimens exhibited dimensional stability at temperatures exceeding 170 °C, thereby demonstrating their viability for steam sterilization procedures. To translate these findings into practical applications, we selected a small, complex geometrically relevant component, the Easy Bone Collector (EBC) shell, for autoclave testing at 134 °C. Post-sterilization, the part successfully retained its shape and functionality, indicating that, with appropriate thermal conditioning, PLA can be effectively utilized to manufacture cost-efficient, autoclavable components suitable for medical use. These results reveal a promising and sustainable approach to producing reusable, sterilization-compatible PLA devices, particularly in low-volume or single-use applications where biodegradability is advantageous.